Vacuum insulated structure tubular cabinet construction
A refrigerator includes a vacuum insulated cabinet structure having side walls that are formed from a tube that has been folded/deformed into a structure having an “O” shape with vertically enlarged front and rear openings. The interior of the tube may be filled with silica powder or other filler, and a vacuum is formed within the tube. An insulated rear panel may be utilized to close off the rear opening of the vacuum insulated cabinet structure.
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The present application is a continuation of U.S. patent application Ser. No. 14/731,796 filed on Jun. 5, 2015 and entitled “VACUUM INSULATED STRUCTURE TUBULAR CABINET CONSTRUCTION,” now U.S. Pat. No. 9,835,369, which issued on Dec. 5, 2017, which is a divisional of U.S. patent application Ser. No. 13/836,143 filed on Mar. 15, 2013, now U.S. Pat. No. 9,071,907, entitled “VACUUM INSULATED STRUCTURE TUBULAR CABINET CONSTRUCTION,” which claims the benefit of U.S. Provisional Patent Application No. 61/618,914 filed on Apr. 2, 2012, entitled “ENERGY EFFICIENT HOME APPLIANCES.” Each of the above-identified applications are hereby incorporated by reference.
The present application is also related to U.S. patent application Ser. No. 13/833,635, filed Mar. 15, 2013, entitled “A METHOD TO CREATE VACUUM INSULATED CABINETS FOR REFRIGERATORS,” now abandoned; and U.S. patent application Ser. No. 13/836,669, filed Mar. 15, 2013, entitled “FOLDED VACUUM INSULATED STRUCTURE,” now U.S. Pat. No. 9,140,481; and U.S. patent application Ser. No. 13/835,449, filed Mar. 15, 2013, entitled “A VACUUM PANEL CABINET STRUCTURE FOR A REFRIGERATOR,” now U.S. Pat. No. 8,944,541; and U.S. patent application Ser. No. 13/832,246, filed Mar. 15, 2013, entitled “DUAL COOLING SYSTEMS TO MINIMIZE OFF-CYCLE MIGRATION LOSS IN REFRIGERATORS WITH A VACUUM INSULATED STRUCTURE,” now U.S. Pat. No. 9,182,158; and U.S. patent application Ser. No. 13/833,696, filed Mar. 15, 2013, entitled “VACUUM INSULATED DOOR STRUCTURE AND METHOD FOR THE CREATION THEREOF,” now U.S. Pat. No. 9,038,403; and U.S. patent application Ser. No. 13/837,659, filed Mar. 15, 2013, entitled “FOLDED VACUUM INSULATED STRUCTURE,” now U.S. Pat. No. 8,986,483; and U.S. patent application Ser. No. 13/833,635, filed Mar. 15, 2013, entitled “METHOD TO CREATE VACUUM INSULATED CABINETS FOR REFRIGERATORS,” now abandoned, all of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTIONVarious types of insulated cabinet structures have been developed for refrigerators, freezers and the like. Known refrigerator cabinet structures may include inner and outer walls with urethane foam or other insulating material disposed between the inner and outer walls.
SUMMARY OF THE INVENTIONOne aspect of the present invention is a method of fabricating a vacuum insulated refrigerator housing. The method includes forming an elongated tube having opposite open ends defining a link therebetween. The tube may be formed from a metal material, or the tube may comprise multiple layers of polymer material, wherein one of the layers is substantially impermeable to gasses such as nitrogen, oxygen and water vapor. The elongated tube has a substantially uniform cross-sectional shape along the length of the tube, and the tube defines generally planar first and second oppositely facing primary outer surfaces. The tube further includes first and second end surfaces extending between the first and second primary outer surfaces. The method further includes forming the tube along at least four fold lines to form at least four corners, whereby portions of the first primary surface adjacent each corner are substantially orthogonal relative to one another. The method further includes sealing the opposite ends of the elongated tube to form an air-tight insulating space within the tube. The opposite ends of the tubes are connected to one another to form a refrigerator housing structure that is generally “O” shaped with horizontally spaced apart, generally vertical side walls and vertically spaced apart generally horizontal upper and lower side walls forming four corners. The refrigerator housing structure defines an internal space having enlarged front and rear openings. The method further includes forming a vacuum in the insulating space within the tube, and attaching an insulated rear panel to the refrigerator housing structure to at least partially close off the enlarged rear opening.
Another aspect of the present invention is a method of forming a vacuum insulated refrigerator housing structure. The method includes forming an elongated tube having opposite ends. The opposite ends are sealed to form an air-tight insulating space within the tube. The method further includes forming a vacuum in the air-tight insulating space, and positioning the opposite ends of the tube adjacent to one another by deforming the tube. The opposite ends are connected together to form a refrigerator housing structure that is generally “O” shaped with spaced apart upright side walls, and spaced apart upper and lower side walls extending between the upright side walls. The refrigerator housing structure defines an internal space and enlarged front and rear openings.
Another aspect of the present invention is a vacuum insulated refrigerator housing structure including a pair of horizontally spaced apart upright side walls defining upper and lower end portions. The vacuum insulated refrigerator housing structure also includes an upper side wall having opposite ends connected to the upper end portions of the upright side walls, and a lower side wall having opposite ends connected to the lower end portions of the upright side walls. The upright side walls and the upper and lower side walls comprise a one-piece integral tubular structure forming air-tight insulating space within the upright side walls and the upper and lower side walls. The air-tight insulating space is evacuated and thus forms a vacuum insulated structure.
These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
With reference to
With further reference to
The tubular primary structure 16 is made from an elongated tube 44 (
With further reference to
After a sufficient length of tubing 44 is extruded (
With further reference to
After formation of indentations 70 and/or 72 and grooves 74 and/or 76, the tube 44 is bent utilizing forming tools 82A-82D to form corners 46A, 46B, 48A and 48B as shown in
With reference to
With further reference to
As discussed above, the tubular primary structure 16 includes enlarged front and rear openings 22 and 24. The openings 22 and 24 generally define a rectangular perimeter 20, and the tubular primary structure 16 has a generally rectangular perimeter 18 in an elevational view (e.g.
With further reference to
Referring again to
The filler material 54 may also be added after the tube 44 is bent into an O-shape (e.g.
Claims
1. A method of fabricating a vacuum insulated refrigerator cabinet structure, the method comprising:
- forming an elongated tube;
- forming a vacuum in an insulating space within the tube;
- filling the insulating space with a porous filler material;
- after filling the insulating space with a porous filler material, forming an airtight insulating space within the tube by sealing off the insulating space to maintain the vacuum in the airtight insulating space within the tube;
- deforming the tube along at least four fold lines to form at least four corners whereby portions of the first primary surface adjacent each corner are substantially orthogonal relative to one another; and
- connecting a movable door to the structure adjacent the front opening whereby the door selectively closes off at least a portion of the front opening when the door is in a closed position,
- wherein forming the elongated tube comprises forming a generally planar first and second oppositely-facing primary outer surfaces and first and second end surface extending between the first and second primary outer surface;
- wherein the insulating space is formed, at least in part, by connecting opposite ends of the tube to one another to form a primary structure having enlarged front and rear openings.
2. The method of claim 1, wherein:
- forming the elongated tube comprises an extrusion process.
3. The method of claim 1, including:
- utilizing an extrusion process to form the elongated tube;
- cutting the elongated tube to length after a sufficient length of the tube is extruded.
4. The method of claim 1, wherein:
- connecting the opposite ends of the tube to one another forms a refrigerator housing structure having horizontally spaced apart generally vertical side walls and vertically spaced apart generally horizontal upper and lower side walls, wherein the refrigerator housing structure defines an internal space with vertically enlarged front and rear openings.
5. The method of claim 4, including:
- attaching an insulated rear panel to the refrigerator housing structure to at least partially close off the enlarged rear opening.
6. The method of claim 1, wherein:
- the tube is formed by extruding a metal material.
7. The method of claim 1, wherein:
- the tube is formed by extruding an impermeable polymer material.
8. The method of claim 1, wherein:
- the tube is formed by extruding first and second layers of polymer material.
9. The method of claim 8, wherein:
- at least one of the first layer and the second layer comprises a substantially impermeable polymer material.
10. The method of claim 9, wherein:
- the first and second layers define substantially uniform first and second thicknesses, respectively, and wherein the first thickness is less than the second thickness.
11. The method of claim 6, wherein:
- connecting the opposite ends of the tube to one another comprises welding the opposite ends together to form a seam.
12. The method of claim 1, including:
- compacting the porous filler material prior to forming a vacuum in the insulating space.
13. The method of claim 12, wherein:
- the porous filler material comprises fumed silica powder.
14. The method of claim 1, wherein:
- the tube is placed in a vacuum chamber prior to forming an airtight insulating space within the tube.
15. The method of claim 1, including:
- forming an indentation at each of the fold lines prior to forming the four corners.
16. The method of claim 1, wherein:
- the tube is formed such that the tube has a substantially uniform cross sectional shape along a length of the tube.
17. The method of claim 1, including:
- securing a rear wall to the primary structure to close off the enlarged rear opening to define an insulated food storage space; and
- connecting a cooling system to the refrigerator cabinet structure to cool the insulated food storage space.
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Type: Grant
Filed: Oct 26, 2017
Date of Patent: May 26, 2020
Patent Publication Number: 20180045455
Assignee: Whirlpool Corporation (Benton Harbor, MI)
Inventors: Steven J. Kuehl (Stevensville, MI), Axel Julio Ramm (Saint Joseph, MI), Guolian Wu (Saint Joseph, MI), James W. Kendall (Mount Prospect, IL), Nihat Cur (Saint Joseph, MI), Paul B. Allard (Stevensville, MI)
Primary Examiner: Christopher J Besler
Application Number: 15/794,785
International Classification: F25D 23/06 (20060101); F25D 11/00 (20060101); F25B 39/02 (20060101); F25D 23/02 (20060101); F25B 39/00 (20060101); B29C 53/00 (20060101); H04R 3/12 (20060101); B23P 15/26 (20060101); F25C 1/00 (20060101);